Plastic materials guide: thermoplastics and thermosets
A practical guide to the plastic materials we process, including ABS, polycarbonate, polypropylene, PEEK and phenolics. Properties, applications and when to use each.
Request a quoteHow to choose the right plastic material
Choosing the right material is one of the most important decisions in any plastic component project. The wrong choice can lead to premature failure, excessive cost, or manufacturing problems. Our team has decades of experience across thermoplastics and thermosets, and we will always recommend the right material for your application - not the easiest one for us to process.
This guide covers the main materials we process - both thermoplastics and thermosets - with a brief description of each material's key properties and the applications it is best suited to.
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Thermoplastic materials
Thermoplastics can be melted and resolidified repeatedly. They are processed by injection moulding and available in a huge range of grades.
Exceptional impact strength and optical clarity. Operating temperature up to 120°C. Used in safety equipment, transparent covers, lighting and electronic enclosures.
The toughness of polycarbonate combined with easier processing and better surface finish of ABS. Ideal for automotive interiors, consumer electronics and medical device housings.
Excellent mechanical strength, toughness and chemical resistance. Available glass-filled for higher stiffness. Used in structural components, gears, bearings, clips and fasteners.
Outstanding dimensional stability, very low friction and excellent fatigue resistance. Ideal for precision gears, bearings, snap-fits and pump components.
Good dimensional stability, chemical resistance and electrical insulation. Fast crystallisation gives short cycle times. Used in electrical connectors and automotive components.
Good all-round material: stiff, impact resistant, easy to process and excellent surface finish. Widely used in consumer goods, electronic housings and engineering components.
The workhorse of injection moulding. Excellent chemical resistance, good fatigue resistance (living hinges), low density and very cost-effective. Food-contact and medical grades available.
LDPE for flexible parts; HDPE for rigid structural applications. Both offer excellent chemical resistance and food-contact compliance.
High-performance polymer. Continuous service to 250°C. Used in aerospace, medical implants and chemical processing where standard polymers are insufficient.
Thermoset materials
Thermosets cure chemically during processing and cannot be re-melted. Processed by compression, transfer or injection-compression moulding.
Phenolic - Phenol Formaldehyde (PF)
Excellent heat resistance (180°C+), dimensional stability and electrical insulation. Used in switches, connectors, oven handles and brake components. Very cost-effective.
DAP - Diallyl Phthalate
Premium electrical thermoset with superior tracking resistance and very low moisture absorption. Used in precision military and aerospace electrical connectors.
Epoxy - Epoxy Moulding Compound
Outstanding adhesion to metals, excellent chemical resistance and dimensional stability. Used in semiconductor encapsulation and structural applications.
DMC/BMC - Dough / Bulk Moulding Compound
Glass-fibre reinforced thermoset. High strength, electrical insulation and fire retardancy. Used in electrical distribution, appliances and automotive under-bonnet parts.
Fire-retardant grades
For electronics, electrical, automotive and construction applications that must meet fire safety standards.
UL94 V0
Self-extinguishing within 10 seconds. The most stringent fire rating. Available in PC, ABS, PA, PBT and PP grades.
Halogen-Free
Environmental and health regulations may prohibit brominated flame retardants. We process halogen-free FR grades for full compliance.
Testing & Certification
We help you identify the correct FR grade and the testing requirements you need to meet. Decades of experience across demanding applications.